Process for making snack foods having two or more filled axial cavities

ABSTRACT

A process for making a tubular shaped hand held convenience snack food type product comprising the steps of formulating dough comprising potato shreds, cellulose gum and starch, extruding the dough through a multiple extrusion nozzle to form continuous ropes having two or more axial cavities which can be filled with savory fillings, optionally compressing the ropes, cutting and crimping ropes to form uncooked cut casings and then cooking and freezing. The dough has a moisture content of about 55% to about 75%, preferably about 60% to about 72%, to facilitate extrusion without impairing the potato shred material.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a Continuation-in-Part of application Ser. No. 09/526,347, filedMar. 16, 2000 entitled “Tube-Shaped Snack Foods and Methods of MakingSame”. This application is also related to U.S. Pat. No. 6,328,550,entitled “Nozzle for Making Snack Foods Having Two or More Filled AxialCavities” which was filed on the same date herewith and is aContinuation-in-Part of said application Ser. No. 09/526,347.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention concerns a process for making hand held and conveniencesnack food products comprising potato shreds. The process comprisesformulating dough having a moisture content of about 55% to about 75%,preferably about 60% to about 72%, comprising potato shreds, cellulosegum, starch and other ingredients. The dough is extruded through amultiple extrusion nozzle, which in preferred embodiments comprises anouter extrusion segment and an inner extrusion segment which can beinserted into the outer extrusion segment to provide for extrusion ofcontinuous ropes or casings having two or more axial cavities which arefilled with savory fillings. If the continuous ropes are not of desiredsize and/or shape following extrusion, the continuous ropes mayoptionally be subjected to a roll over operation. The continuous ropesare cut and crimped to form uncooked cut casings. The uncooked cutcasings are then cooked by baking, frying, par-baking or par-frying,combinations thereof or otherwise, and frozen to obtain the handheldconvenience snack food product.

2. The Related Art

Hand held convenience snack foods having a filling surrounded by acasing typically have casings made from bakery formulas involving pastrydough. Bakery formulas generally involve grains and flours and thepastry dough tends to be homogenous which is both easy to form byextrusion or other means, or otherwise easy to fill. An example iscereal bar mixes made with pastry dough comprising multi-grains, andalthough these materials tend to have coarser grains compared to otherpastry dough ingredients, the particles have substantial uniformity thusfacilitating extrusion and filling.

Potato shreds are nonuniform and have bigger and longer particle sizecompared to grains and flours. As a result, dough comprising potatoshreds lacks uniformity and is more difficult to handle and extrude.Dough comprising potato shreds will have the tendency to form opensurfaces after extrusion or during the forming or filling process.

U.S. Pat. No. 4,888,192 concerns a method of extruding baked goods inthe form of an extruded rope comprised of three materials. An outerexpanded crispy layer and two non-dough filler materials are describedas components. The dough is extruded under pressure and expands uponrelease from the nozzle surrounding a pair of tubes which place thefilling into the center of the tubes. The filling material is suppliedto the extruder through separate tubes and there is no discussion in thepatent that the nozzle and/or extruder can be used to extrude doughcomprising potato shreds.

U.S. Pat. No. 4,259,051 addresses extrusion apparatus for forming ahollow foodstuff of extruded plastic material which can besimultaneously filled. There is no discussion in the patent that theapparatus can be used for potato shred dough, and the apparatus cannotlikely be used for extruding a plurality of axial cavities.

U.S. Pat. No. 5,527,179 describes an apparatus for extruding dough inhollow form through the use of a solid pin within the extrusion nozzle.U.S. Pat. No. 4,900,572 describes an apparatus for making dog food wherean outer layer is extruded into a chamber having sleeves. An inner layeris extruded through the sleeves and, thus, the inner layer becomescovered by the outer layer. U.S. Pat. No. 5,645,872 describes extrusionof hollow shapes of material subject to coagulation by allowing gas orliquid to flow into the center cavity after extrusion to fostercoagulation and avoid collapse of the hollow extruded shape.

U.S. Pat. No. 4,828,856 describes hash brown type potato products madefrom de-hydrated formed or fabricated potato shreds which can bere-hydrated and formed into patties said to simulate fresh cut potatoproducts. The re-hydrated mass has a moisture content of 40% to 55% sothat the product can be sheeted with a 1 to 2 millimeter opening betweensheeting rolls. The potato dough made from the shreds described in thispatent cannot be extruded because of needed high extrusion pressureswhich are said to rupture a significant portion of the potato cells.Non-critical ingredients for these products are carboxymethylcellulose,which is said to be a processing aid for the sheeting operation, andcertain food gums to reduce fat or oil pickup (uptake) during frying.U.S. Pat. No. 5,492,704 describes a process for making potato strandscomprising shreds for use in hash brown potatoes, and re-hydration ofthe shreds in the form of sheets to make a hash brown potato product isexemplified in the patent.

U.S. Pat. No. 5,891,596 describes potato mixtures shaped by extrusion orotherwise that are processed as a reduced fat flash frozen potatoproduct. The formed potato shapes are made from blended potato pieces,and the blended product contains small pieces and, thus, not potatoshreds. U.S. Pat. No. 3,399,062 describes dehydrated granular products,such as crushed dehydrated potatoes, containing some aggregates ofindividual cells, re-hydrated at low temperature in the presence ofcellulose ether thermal gelling agent and extruded to obtain a frenchfried potato product.

U.S. Pat. No. 3,975,549 describes agglomerated dehydrated potatoproducts made from dehydrated potato particles that, after re-hydrationwith a binder, are extruded to form french fries. The binder may beeither a gum, such as guar gum, or free starch from modifying the potatosolids. U.S. Pat. No. 3,987,210 describes an extruded french friedpotato product comprising dehydrated potatoes in the form of flakes,granules, flour, diced pieces or mixtures thereof with a bindercomprising more than about 25% amylose starch. The starch is said toretrograde when heated with water to form a film around the product andprovide an oil barrier.

U.S. Pat. No. 3,486,673 describes extruded french fried potato productscomprising dehydrated mashed potatoes, methyl cellulose andpolygalacomannan gum, which are said to be essential ingredients. Thecombination of ingredients reportedly provide the product with anirregular external crust which permits the product to pick up a modestamount oil during frying. U.S. Pat. No. 5,242,699 addresses anapplication of a hydrocolloid coating to potato strips to provide anexterior crust when the strips are blanched or par-fried which may alsoretard oil adsorption into the potato strip. U.S. Pat. No. 5,620,727concerns use of low molecular weight ionic hydrocolloid compositions tomake film to reduce oil uptake. U.S. Pat. No. 3,687,688 concernsimmersion of potato into a batter comprising sodium alginate formoisture control, and U.S. Pat. No. 4,900,573 concerns batter comprisinghydroxypropyl methylcellulose which is said to function as an oilbarrier.

Fat absorption/uptake of fried foods is one of the major concerns ofconsumers, particularly with respect to dietary concerns as fat providesapproximately 9 calories. per gram to the food. Also, fat leaching froma prepared product during re-heating or reconstituting causes a greasyfeel to food, and imparts undesirable organoleptic qualities to thefood.

An object of the invention is a process that allows for the extrusionand processing of dough material comprising potato shreds to obtain anorganoleptically acceptable and pleasing hand held convenience snackfood, which can be easily reconstituted by the consumer, having a casingwith axial cavities and savory fillings. These objects are achieved bythe process and equipment described herein, particularly with regard tothe moisture content of the dough material which enables extrusionwithout impairing the characteristics of the potato shred dough, themultiple extrusion nozzle and the cutting and crimping step of theprocess which isolates the savory filling material within the casing.

It is a further object of the invention to enable extrusion of a producthaving an outer casing with one or more axial indented ridge typeconnectors that allows sections of the casing to be broken apart so thatthe product can be consumed individually. A further object of theinvention is the filling of the axial cavities simultaneously withextrusion. These, and other objectives of the invention, are achieved bythe process and apparatus described herein.

Other objects of the invention are to make a hand held convenience snackfood product that comprises a casing with potato shreds that can beextruded in the multiple extrusion nozzle and filled and then cooked,such as partially or fully fried or baked, without significant excessoil absorption during cooking and without oil or fat leaching duringreconstitution and an extrudable casing comprising potato shreds thathas structural integrity which can withstand the extrusion and fillingprocess, and other processing to, in certain embodiments, axially joinouter walls of two or more casings. These objectives are achieved by theunique potato shred matrix of the casing and the selection of cellulosegums which, with starch, forms a film on the exposed surfaces of thecasing filling the voids in the potato shred matrix on exposed surfaces,which strengthens the matrix and inhibits oil/moisture transmission.These objectives are further achieved by the incorporation of axialindented ridge type connectors.

The process provides for an extruded baked or fried product comprisingpotato shreds wherein the integrity of the shreds is maintained despitethe extrusion process. The cellulose gums and starch form a film aroundthe exposed surfaces of the potato shred casing filling the voids at theexposed surfaces of the casing. As such, the casing maintains its shapeduring and after extrusion and the film helps control both oil pick-upduring cooking and oil or fat leaching when the product isreconstituted. The moisture content is also important to processabilityas the moisture content of the casing, about 55% to about 75%,preferably about 60% to about 72%, regulates oil uptake during cookingin addition to facilitating extrusion.

In the present Specification, all parts and percentages are byweight/weight unless otherwise specified.

SUMMARY OF THE INVENTION

The process for making the snack food products comprises several steps.In general, the hand held and convenience snack products are formed fromcontinuous ropes (referred to herein interchangeably as casings, ropesand continuous ropes), that are either hollow or solid. In the preferredembodiment, the casing is hollow and extruded through a multipleextrusion nozzle which provides for a casing having two or more innerwalls, an outer wall and two or more axial cavities, such as two orthree axial cavities defined by the inner walls, which. can be filledwith a variety of savory fillings, such as meats, cheeses, or otherprocessed dairy products, flavorings, spices, sauces and the like, orcombinations of these. The casings are formed with axial indented ridgetype connectors and can be radially cut to a lengthwise size toaccommodate reconstitution, e.g., re-heating, in a conventionalresidential toaster or toaster oven. When the casing is cut, the casingis crimped to form ends of potato shred casing material which seals thefilling within the axial cavities and the ends. In yet anotherembodiment of the invention, two or more ropes can be axially attachedafter extrusion. The details of the process and the various steps arediscussed herein.

The casings comprise potato shreds which can be fresh cut or dehydrated,or a combination of fresh cut and dehydrated. The casing furthercomprises cellulose gum and starch, preferably modified starch, whichform a film and fill voids in the potato shred matrix at the exposedsurfaces of the casing, and serves to facilitate a stable potato shredmatrix and provides a fat/moisture barrier for the casing material.Cellulose gums useful for the casing are microcrystalline cellulose,methylcellulose, carboxymethylcellulose, hydroxyethylcellulose,hydroxypropylcellulose, hydroxypropylmethylcellulose or combinationsthereof. The matrix is critical to the mechanical properties of theproduct and, together with the moisture content of the extruded casing,allows for extrusion of the casing with sufficient structural support,particularly when the casing is extruded having one or more axialcavities so that the casing material will not generally collapse intothe axial cavities. The film regulates moisture loss during frying tocontrol fat uptake, and also retards fat from leaching from the productduring reconstitution. The snack food product can be reconstituted by anumber of means, including oven cooking, microwave cooking and heatingin a conventional residential toaster or toaster oven. Leaching of fatduring preparation would result in a greasy texture to the outer surfaceof the casing and poor organoleptic qualities. Thus, the matrix and filmformed by the interaction of the gum and starch and potato shredsprovide for an organoleptically acceptable product with a hash brownlike texture and, particularly in the methods of toaster or toaster ovenpreparation, a product that will not undesirably leach oil or fat duringre-heating or reconstitution.

The casing can comprise dehydrated potato shreds, fresh cut potatoshreds or combinations thereof. When dehydrated potato shreds are used,the casing comprises about 20% to about 24% dehydrated potato shreds,about 3% to about 10% dried potato flakes, about 1% to about 4% starch,about 0.5% to about 2% flavorings, about 0.5% to about 2% sweetener,preferably dextrose, about 0.5% to about 2.5% cellulose gum and about55% to about 75% water, preferably about 60% to about 72%. When freshcut potato shreds are used, the casing comprises about 75% to about 95%fresh cut potato shreds, which may be moisture adjusted (e.g.dehydrated) to a moisture content of about 55% to about 75%, preferablyabout 60% to about 72%, about 3% to about 10% dried potato flakes, about1% to about 4% starch, about 0.5% to about 2% flavorings, about 0.5% toabout 2% sweetener, preferably dextrose, and about 0.5% to about 2.5%cellulose gum. Potato shreds as discussed herein are rectangular shapedpotato pieces of random axial length, preferably up to about 76millimeters, and a cross section of from about 6.4 millimeters to about2.5 millimeters by about 3.2 millimeters to about 6.4 millimeters,preferably about 4.0 millimeters to about 2.5 millimeters by about 4.8millimeters, and may be in dehydrated form.

The ingredients of the casing are mixed together and then the mixture isextruded through a multiple extrusion nozzle or a series of multipleextrusion nozzles to obtain one, or two or more cylindrically toelliptically shaped casings in the form of continuous ropes. In apreferred embodiment of the invention, the casing is extruded in hollowform, (i.e. tube like, having two or more axial cavities) and thenfilling is either co-extruded with the casing, injected into the axialcavities or stuffed into the axial cavities. The ropes are extrudedthrough a multiple extrusion nozzle that provides for two or more axialcavities, preferably two or three axial cavities. Continuous ropescomprising a plurality of axial cavities can be extruded with axialintended ridge type connectors having radial widths of about 2 to about12 millimeters formed at the outer surface of the casing material in theregion between the axial cavities. The region between the axial cavitiesbeing the area of the extruded casing where the casing material is solidwithout the gap in casing material defined by an axial cavity.

The multiple extrusion nozzle comprises an outer extrusion segment andan inner extrusion segment which is inserted within the outer extrusionsegment to enable extrusion of casing material with two or more axialcavities. Dough, preferably dough comprising potato shreds, is extrudedthrough the annular space formed by the inside wall of the outerextrusion port of the outer extrusion segment and the outside wall ofthe inner extrusion port of the inner extrusion segment, thereby forminga potato shred casing having two or more axial cavities, such as two orthree axial cavities. The savory filling materials are extruded,injected, or stuffed into the axial cavities through the inner extrusionsegment. The multiple extrusion nozzle also forms a plurality of axialindented ridge type connectors by indentations in the outer extrusionsegment. The multiple extrusion nozzle can also be used to extrudebakery dough comprising grain and/or flour.

If a snack food product comprising more axial cavities than are extrudedin the casings is desired, a plurality of continuous ropes can beextruded on a conveyor. As the continuous ropes move on the conveyor,the continuous ropes physically move together, either through themovement of the conveyor or by physical means such as guides or wedges,and become connected at adjacent axial portions of outer walls of thecasings to form a tube shaped snack food comprising two or more axiallyconnected continuous ropes. By way of example and not limitation,casings each comprising two filled axial cavities can be attachedlengthwise to form a set of attached casings comprising four axialcavities. An axial indented ridge type connector having a radial widthof about 2 to about 12 millimeters is formed along adjacent outer wallsof the axially connected continuous ropes. This axial indented ridgetype connector is in addition to those formed within the continuousropes during extrusion. The axial indented ridge type connectors providethe product with pull apart functionality, and adds rigidity to thecasing of the overall product.

If the continuous ropes are not of a desired size or shape afterextrusion, the continuous ropes may be subjected to a roll overoperation which involves moving the continuous ropes under one or morerollers that compress the continuous ropes as desired. The ropes are cutradially to a desired length, to accommodate the method of preparationand size of equipment, (e.g. oven, microwave oven, toaster, etc.) forreconstitution, and the ropes are crimped at the time they are cut toform ends of potato shred casing material which seals the filling withinthe axial cavities and ends.

The cutting and crimping of the continuous ropes results in uncooked cutcasings which are then cooked by frying or baking, including par-fryingor par-baking and then frozen. The product can be reconstituted orreheated by means, such as a toaster, toaster oven or oven, or bymicrowave heating. The gum and starch provide a film around the casingwhich in part, inhibits the leaching of oil from the product duringreconstitution thereby providing the product with acceptableorganoleptic properties and texture, and reduced undesired greasy feeland, thus, the product has particular utility for hand held consumption.The gum and film also serves to enhance the structural support of thecasing.

The process allows significant variation in product dimensions,particularly axial length, to accommodate differences in equipment sizesfor re-heating and for future modifications by equipment manufacturers.The ability to vary the size of the product also allows for products tomeet particular consumer choices. For example, the product can be cut toan axial length of about 8.5 centimeters to about 11 centimeters forcurrent conventional toasters or toaster ovens, or could be cut longerfor oven preparation or smaller to make a single serving pieces or horsd'oeuvres. The thickness is determined by some or all of thefollowing: 1) the extrusion parameters, 2) the roll over operation and3) the outer extrusion port of the multiple extrusion nozzle. The lengthis determined by cutting. The width is a function of 1) the size of thecontinuous ropes and 2) the number of continuous ropes axially attachedtogether.

DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top view elevation of the hand held snack food product in anembodiment where a continuous rope having two filled axial cavities iscut and crimped for toaster or toaster oven preparation.

FIG. 2 is a cross sectioned view along line 2—2 of FIG. 1.

FIG. 3 is a cross sectioned view of a continuous rope having two filledaxial cavities.

FIG. 4 is an end view elevation of the hand held snack food product inan embodiment where a continuous rope having two axial cavities is cutand crimped for toaster or toaster oven preparation.

FIG. 5 is a front view elevation of the outer extrusion segment in anembodiment where two axial cavities are formed by extrusion.

FIG. 6 is a side view elevation of the outer extrusion segment in anembodiment where two axial cavities are formed by extrusion.

FIG. 7 is a top view elevation of the outer extrusion segment in anembodiment where two axial cavities are formed by extrusion.

FIG. 8 is a front view elevation of the inner extrusion segment in anembodiment where two axial cavities are formed by extrusion.

FIG. 9 is a top view elevation of the inner extrusion segment in anembodiment where two axial cavities are formed by extrusion.

FIG. 10 is a side view elevation of the inner extrusion segment in anembodiment where two axial cavities are formed by extrusion.

FIG. 11 is a front view elevation of the multiple extrusion nozzlehaving an inner extrusion segment inserted within the outer extrusionsegment in an embodiment where two axial cavities are formed byextrusion.

FIG. 12 is a front view elevation of the outer extrusion segment in anembodiment where three axial cavities are formed by extrusion.

FIG. 13 is a side view elevation of the outer extrusion segment in anembodiment where three axial cavities are formed by extrusion.

FIG. 14 is a top view elevation of the outer extrusion segment in anembodiment where three axial cavities are formed by extrusion.

FIG. 15 is a front view elevation of the inner extrusion segment in anembodiment where three axial cavities are formed by extrusion.

FIG. 16 is a top view elevation of the inner extrusion segment in anembodiment where three axial cavities are formed by extrusion.

FIG. 17 is a side view elevation of the inner extrusion segment in anembodiment where three axial cavities are formed by extrusion.

FIG. 18 is a front view elevation of the multiple extrusion nozzlehaving an inner extrusion segment inserted within the outer extrusionsegment in an embodiment where three axial cavities are formed byextrusion.

DETAILED DESCRIPTION OF THE INVENTION

The process provides for a tubular hand held convenience snack foodproduct comprising a potato shred dough casing material that isextruded, preferably with axial cavities that are filled with a varietyof savory fillings. The process generally involves the following steps.

1. Formulating dough having a moisture content of about 55% to about75%, preferably about 60% to about 72%, which comprises potato shreds,either fresh cut and/or dehydrated, cellulose gum, starch and other dryingredients.

2. Extruding the dough, preferably through a multiple extrusion nozzlewhich forms a continuous rope having two or more axial cavities andfilling the axial cavities with savory filling materials by extrusion,injection, stuffing or otherwise through the multiple extrusion nozzle.

3. Optionally, compressing the continuous ropes through a roll overoperation.

4. Cutting and crimping the continuous ropes, preferably to a size ofabout 8.5 centimeters to about 11 centimeters, to obtain uncooked cutcasings having filling material generally sealed within the axialcavities and ends.

5. Cooking the uncooked cut casings by frying, par-frying, baking and/orpar baking to obtain a product.

6. Freezing the product.

The hand held snack foods are a convenience food product designed tomove from the package to serving with merely reconstitution, such asre-heating, by the consumer. Referring to FIGS. 1-4, the hand held snackfood product 1 is generally depicted in FIG. 1. The product comprises adual cylindrical shaped casing (continuous ropes) 2 and filling 3 inaxial cavities defined by inner walls 4 of the casing 2 as shown inFIGS. 2 and 3. An axial indented ridge type connector 5 is formedlengthwise in the top and bottom of the outer surface of the potatocasing in the region of solid casing material between regions of hollowcasing (e.g. at the locations of the axial cavities) as shown in FIGS.1-3. It is to be understood that while FIGS. 1-3 show a product wheretwo axial cavities are formed together with an axial indented ridge typeconnector 5, continuous ropes, hollow and filled or solid, can have anynumber of axial cavities with lengthwise axial indented ridge typeconnectors. In embodiments of invention having three axial cavities, forexample, the product would have two axial indented ridge typeconnectors. Generally, the number of axial indented ridge typeconnectors will be one less than the number of axial cavities. When theproduct is cut and crimped, the product comprises at least one end 7 asshown in FIGS. 1 and 4; of casing material which encloses the fillingwithin the inner walls 4 of the casing and ends 7 forming uncooked cutcasings wherein the filling is generally isolated within potato shredcasing material.

The continuous ropes are extruded through a multiple extrusion nozzlewhich extrudes casing having two or more axial cavities, preferably twoor three axial cavities, and the axial cavities are filled by extrusion,injection or stuffing of savory fillings through the multiple extrusionnozzle. The nozzle can be adapted to fit standard commercial foodextruders, such as co-extruders available from Rheon, USA, Huntersville,N.C., USA, and non-traditional extrusion equipment such as continuousvacuum stuffers, pumper-stuffer equipment and other modifiedco-extrusion equipment.

The multiple extrusion nozzle is illustrated in FIGS. 5-18 with respectto embodiments where continuous ropes comprising two and three axialcavities are extruded. The multiple extrusion nozzle, as shown in FIGS.11 and 18, comprise an outer extrusion segment 10 and 10 a and an innerextrusion segment 18 and 18 a. Dough, preferably dough comprising potatoshreds as described herein, is extruded through the annular space 27 and27 a to form a continuous rope having axial cavities, and the axialcavities are filled through the inner port openings 29 and 29 a of theinner extrusion ports 21 and 21 a of the inner extrusion segment 18 and18 a. Indentations 28 and 28 a form the axial indented ridge typeconnectors 5 as shown in FIGS. 1-3. The filled casings are cut andprocessed as described herein to form the snack food product 1 as shownin FIGS. 1-4.

The outer extrusion segment 10 is shown generally in FIGS. 5-7.Referring to FIGS. 5-7, the outer extrusion segment 10 comprises a body11 which has an outer surface 12 and an inner surface 13, preferablyconical shaped, which forms a hollow section 14, preferably conicalshaped, defined by the inner surface 13 that terminates at one end withan outer extrusion port 15 and at the opposite end in an opening 16. Theouter extrusion port 15 may be any shape, but is preferably shaped as amodified ellipse as shown in FIGS. 5-7 and FIG. 11. Generally, the outerextrusion port 15 is smaller in dimension than the opening 16, anddough, preferably dough comprising potato shreds, enters the opening 16from the extruder and flows through the hollow section 14 to the outerextrusion port 15 from which the dough is extruded.

At least one set of indentations 28 are formed in the inner surface 13adjacent to and extending to the outer extrusion port 15. The separateindentations of each set 28 are positioned opposite to each other in anupper and lower orientation and form the axial indented ridge typeconnectors in the outer surface of the casings.

A protruding flange 17 which protrudes radially from the outer surface12 is formed on the body 11, functions as a means to secure the outerextrusion segment 10 to a co-extruder. Generally, the flange is seatedwithin an outlet of the co-extruder and a threaded hollow cap (notshown) having a means for sealing the fastening connection, such as agasket or o-ring, mates with the threaded outer surface of outlet tosecure the outer extrusion segment to the co-extruder.

Referring again to FIGS. 5-7 and also to FIG. 11, dough, such as doughcomprising potato shreds, can be extruded through the outer extrusionport 15 to form a solid shaped article which can then be furtherprocessed as described herein. In the preferred embodiment of theinvention, however, the multiple extrusion nozzle provides for extrusionof two or more axial cavities. In an embodiment of the inventionproviding for a product having two axial cavities shown in FIG. 11, aninner extrusion segment 18 (as shown in FIGS. 8-10) is used inconjunction with the outer extrusion segment 10 to form the multipleextrusion nozzle 25. In an embodiment of the invention providing for aproduct having three axial cavities, as shown in FIG. 18, an innerextrusion segment 18a (as shown in FIGS. 15-17) is used in conjunctionwith the outer extrusion segment 10a (as shown in FIGS. 12-14) to formthe multiple extrusion nozzle 25 a. The multiple extrusion nozzle 25 (25a), namely the outer extrusion segment 10 (10 a) and inner extrusionsegment 18 (18 a), can be made of any material appropriate or permittedfor food processing such as plastics, ceramics, stainless steel or anyother food grade material and the separate components of a particularmultiple extrusion nozzle 25 (25 a) can be made from different materialsprovided each material is acceptable for food processing.

The inner extrusion segment 18 is shown generally in FIGS. 8-10 withrespect to the embodiments providing for two axial cavities. Referringto FIGS. 8-10, the inner extrusion segment 18 comprises a shaped body 19having on one end a threaded section 20, which threadably mates with aco-extruder, and at the other end at least one inner extrusion port 21having at least two, preferably two or three inner port openings 29. Thematerial of the inner extrusion port 21 between the inner port openings29 can be of any thickness not exceeding the dimension of the innerextrusion port 21 in the area of the inner port openings 29. The shapedbody 19 will comprise at least one, preferably two or three, channels 22for material flow. FIGS. 8-11 illustrate an embodiment of the inventionwhere the inner extrusion segment comprises two separated, innerchannels 22 for extruding an article with two axial cavities. Thechannels 22 are hollow having diverging axes which are interspacedbetween the threaded section and inner extrusion port 21 and thechannels are aligned with the inner port openings 29 of the innerextrusion port 21. The channels 22 may have any axial length between thethreaded section and inner extrusion port 21, e.g. a single channel mayexist at the threaded section which then splits into separate channelsprior to the inner extrusion port 21 or the channels may originate at ornear the threaded section 20. While FIGS. 8-11 show an embodiment of themultiple extrusion nozzle 25 adapted for making an article having twoaxial cavities, it should be understood that the number of axialcavities will be a function of the number of channels 22 and inner portopenings 29 of the inner extrusion segment 18.

The multiple extrusion nozzle comprises the outer extrusion segment 10with the inner extrusion segment 18 inserted into the hollow section 14.The outer extrusion segment 10 and inner extrusion segment 18 areradially aligned. As shown in FIG. 11 with respect to the embodiment ofthe invention wherein the multiple extrusion nozzle is adapted for twoaxial cavities, the inner extrusion port 21 is interspaced within theouter extrusion port 15, thus forming an annular space 27 between theoutside wall 24 of the inner extrusion port 21 and the inside wall 23 ofthe outer extrusion port 15. The outer extrusion port 15 and innerextrusion port 21 are generally flush with respect to each other, i.e.their open ends are in the same plane, however, there may be a smallamount of clearance between the inner extrusion port 21 and outerextrusion port 15 to allow the dough to completely surround the axialcavities and form the inner walls of the casing material before thecasing material exits the multiple extrusion nozzle and this clearanceis created by moving the open end of the inner extrusion port 21relative to the open end of the outer extrusion port 15 so that theyopen into separate parallel planes. In other words the open end of theinner extrusion port 21 can extend beyond the plane defined by the openend of the outer extrusion port 15 or the open end of the outerextrusion port 15 can extend beyond by the open end of the innerextrusion port 21.

As discussed herein, the multiple extrusion nozzle and component partscan be modified to accommodate extrusion of continuous ropes having aplurality of axial cavities. FIGS. 12-18 illustrate an embodiment of themultiple extrusion nozzle and component parts for extrusion with threeaxial cavities. The component parts illustrated in FIGS. 12-18 numbered10 a to 29 a correspond to the component parts described herein andillustrated in FIGS. 8-11 with respect to extrusion with two axialcavities. The multiple extrusion nozzle providing for three axialcavities functions in the same manner and can be secured to aco-extruder in the same manner as described herein with respect to theinvention in general and the embodiment whereby two axial cavities areformed.

Referring to FIGS. 5-18, dough, preferably dough comprising potatoshreds, moves through the inner section 14 (14 a) of the outer extrusionsegment 10 (10 a) to the outer extrusion port 15 (15 a) from which thedough moves through the annular space 27 (27 a) from the multipleextrusion nozzle thus forming a casing comprising two or more axialcavities. The inner extrusion segment 18 (18 a) is placed into the innersection 14 (14 a) and forms the axial cavity in the casing material bycreating the annular space 27 (27 a) within the outer extrusion port 15(15 a). Filling material is either extruded, injected or stuffed intothe axial cavities through the inner port openings 29 (29 a) of theinner extrusion port or ports 21 (21 a).

By way of example, the multiple extrusion nozzle 25 (25 a) can beincorporated into a commercially available extruder as follows. Theinner extrusion segment 18 (18 a) can be attached by threaded means tothe inner flow of a dual zone extruder, or material supply means, suchas pipes or tubes and thereby secured to a supply of filling material.The outer extrusion segment 10 (10 a) is then attached to the extruderat the protruding flange 17 (17 a) by securing means, such as a lockingmechanism like the hollow cap described herein or by fasteners or thelike such that the inner extrusion segment 18 (18 a) is placed withinthe hollow section 14 (14 a) of the outer extrusion segment 10 (10 a).This arrangement is generally shown in FIG. 11 with respect to an innerextrusion segment 18 having two channels 22 and two inner port openings29 of the inner extrusion port 21, and FIG. 18 with respect to an innerextrusion segment 18 a having three channels 22 a and three inner portopenings 29 a of the inner extrusion ports 21 a.

Sets of indentations 28 (28 a) on the inner surface 13 (13 a) form theaxial indented ridge type connectors for the snack food product. Thesets of indentations, which may be a small pieces of material, such asplastic or metal, is generally molded into or affixed to the innersurface by fastening means to accommodate extrusion of the casingmaterial having any number of axial cavities. FIGS. 5-7 and 11illustrate an embodiment where the outer extrusion segment 10 comprisesone set of indentations located in the top and bottom of the area of theinner surface 13 between corresponding channels 22 and inner portopenings 29 of the inner extrusion segment 18. FIGS. 12-14 and 18illustrate an embodiment where the outer extrusion segment 10 acomprises two sets of indentations located in the top and bottom of thearea of the inner surface 13 a between corresponding channels 22 a andinner port openings 29 a of the inner extrusion segment 18 a. Ingeneral, the number of indentations will be one less than the number ofchannels of the inner extrusion segment, and will be located in the topand bottom of the inner surface between corresponding adjacent channelsof the inner extrusion segment.

The axial indented ridge type connector as shown in FIGS. 1-3 preferablyhas a radial width of about 2 to about 12 millimeters. The axialindented ridge type connector allows the casings to be broken or splitapart lengthwise without the aid of any utensils or tools. The productbreaks at the axial indented ridge type connector without breaking thewalls of the casing at the area of the axial cavities, (e.g. withoutbreaching the axial cavities) and exposing filling or impairing thebasic structure of the casings. Thus, the product can be broken down toserving sizes without the risk of filling escaping out from the casingduring reconstitution and/or consumption. Accordingly, the product canbe a hand held convenience food product.

The product comprises potato shreds and has a casing comprising potatoshreds, cellulose gum, starch, and savory fillings which can be anyvariety of dairy or meat based substances, such as meat, cheeses orother processed dairy foods, flavorings, sauces, spices and the like,and combinations of these. The potato shreds have random length,preferably up to about 76 millimeters, and a cross section of from about6.4 millimeters to about 2.5 millimeters by about 3.2 millimeters toabout 6.4 millimeters, preferably about 4.0 millimeters to about 2.5millimeters by about 4.8 millimeters.

The moisture content of the casing is important for extrusion of thepotato shred and for the properties of the cooked product. A moisturecontent of between about 55% and about 75%, preferably about 60% toabout 72%, provides sufficient moisture to form a flowable potato shreddough. Thus, for example, the dough can be extruded in a dualcylindrical shape in either solid form or with one or two axialcavities, without significant damage to the particulate structure of thepotato and without impairment of the organoleptic characteristics of thepotato shreds. If the moisture content is too low, the casing dough,including the potato shreds will tend to swell during extrusion creatingdifficulties with the extrusion, such as significant breakdown ordestruction of the shred and individual potato particles so that theshreds lose their character, texture and organoleptic qualities. Oneskilled in the art would appreciate that extrusion of the casing with aplurality of axial cavities enhances the difficulty in extrusion ofdough comprising potato shreds as the annular space for flow-through ofcasing material is of decreased size compared to extrusion of a solidrope. Low moisture content will also cause discontinuities in the outersurface of the casing and potato shred matrix and insufficient formationof the film or filling of the void spaces in the matrix on the exposedsurfaces of the casing by the gum and starch which can result inundesired product properties, including appearance, taste, organolepticcharacteristics and undesired oil uptake during cooking, and leachingduring reconstitution. If the moisture content is too high, uncookedcasings, such as uncooked cut casings, will take up a greater amount offat during frying because repelled moisture during cooking is replacedwith fat, thus resulting in poor organoleptic qualities and texture andundesired greasy feel and taste of the product after reconstitution.Accordingly, the moisture content regulates fat uptake.

The casing can be made with either fresh cut potato shreds or dehydratedpotato shreds or combinations thereof. Fresh cut shreds are made fromfresh potatoes which are comminuted by conventional means such asricing, cutting, grinding or milling, and then the comminuted particlesare sieved to obtain the desired size. Dehydrated potato shreds may befresh cut dehydrated pieces. Fresh cut and dehydrated potato shreds areavailable from Nonpareil Co., Blackfoot, Id., U.S.A. The source or typeof shred is not critical to the invention. The casing also comprisesdried potato flakes which can be in the form of granulated, mashed orother processed potatoes and potato pieces.

When de-hydrated potato shreds are used, the casing comprises about 20%to about 24% dehydrated potato shreds, about 3% to about 10% driedpotato flakes, about 1% to about 4% starch, preferably modified starch,about 0.5% to about 2% flavorings, about 0.5% to about 2% sweetener,preferably dextrose, about 0.5% to about 2.5% cellulose gum and about55% to about 75% water, preferably about 60% to about 72% water. Whenfresh cut potato shreds are used, the casing comprises about 75% toabout 95% fresh cut potato shreds, which may be adjusted (e.g. partiallydehydrated) to a moisture content of about 55% to about 75%, preferablyabout 60% to about 72%; about 3% to about 10% dried potato flakes, about1% to about 4% starch, preferably modified starch, about 0.5% to about2% flavorings, about 0.5% to about 2% sweetener, preferably dextrose andabout 0.5% to about 2.5% cellulose gum.

The dehydrated potato shreds and added water, or freshly cut shreds, arecombined with the other ingredients to form a mixture. The mixture isthen extruded through the multiple extrusion nozzle to form one, or twoor more, continuous ropes of material each comprising two or more axialcavities, such as two or three axial cavities. The continuous ropes maybe in the form of a casing material in cylindrical form as shown inFIGS. 1-4 having inner walls 4, an outer wall 6 and axial cavitiesdefined by the inner walls 4, and the axial cavities may be filled withfilling material 3. The multiple extrusion nozzle arrangement formscasing with two or more axial cavities and having a lengthwise axialindented ridge type connectors as shown in FIGS. 1-3. The ropes, whichmay be hollow and filled with savory filling are cut and crimped to formends 7 of potato shred casing material as shown in FIGS. 1 and 4, whichencloses the filling within the axial cavity and ends 7 forming uncookedcut casings. In a preferred embodiment, the ropes are cut into lengthsto accommodate reconstitution by re-heating in current conventionalresidential toasters or toaster ovens. The dimensions of the product canvary by processing conditions to accommodate different sizes ofequipment for re-heating and future size changes, and to providedifferent sized products for consumer choice.

The first step in the process of making the snack food product concernspreparation of the potato shreds for extrusion. When fresh cut shreds,or a combination of fresh cut shreds and dehydrated shreds are used,re-hydration may not be necessary provided the moisture content issufficient to obtain a dough with a moisture content of between about55% and about 75%. When dehydrated potato shreds are used, the shredsmust be re-hydrated to obtain a dough having a moisture content of about55% to about 75% prior to further processing. In either embodiment thepreferred moisture content of the casing material prior to extrusion andcooking is between about 60% and about 72%. Dehydrated shreds arere-hydrated with water at a temperature of about 45° C. to about 95° C.for about 18 to about 60 minutes with, if needed, interval mixing ofabout 1 to about 1.5 minutes about every 3 to 5 minutes during the timeperiod. Mixing can be performed in any vessel, including those capableof interval mixing, such as a standard paddle mixer available fromHobart Corporation, Troy, Ohio, U.S.A. or a ribbon type mixer. Thesemixers are understood in the art and require no further discussion.

The total mixing time and intervals for re-hydration of the dehydratedpotato shreds is a function of the water temperature, and re-hydrationof the shreds is possible at water temperatures less than about 45° C.or greater than about 95° C. When temperatures lower than about 45° C.are used for re-hydration, an acceptable casing is feasible, however themixing and standing intervals are too great for making a product on acommercial basis, as the re-hydration process can take overnight or morethan 24 hours. Water temperatures above about 95° C. will have anadverse effect on the potato shred.

After the dehydrated shreds are re-hydrated; or if fresh cut potatoshreds are used, after the moisture content is adjusted to obtain adough having a moisture content in the range of between about 55% andabout 75%, preferably about 60% to about 72%; other dry ingredients canthen combined with the potato shreds, although the other dry ingredientscan be added during the re-hydration. Preferably, however, all or someof these other dry ingredients, such as dried potato flakes, starch,flavorings, (e.g. onion flakes or powder), sweetener, preferablydextrose, and cellulose gum, are added after re-hydration of dehydratedpotato shreds to avoid competition for water between the shreds andother ingredients during the re-hydration which could affect completehydration of the dehydrated potato shreds. The cellulose gum and/orflavorings, for example, can be combined and mixed with or dispersed inthe water used for re-hydrating the potato shreds either prior to orduring the re-hydration step, or the cellulose gum can be added with theother ingredients after re-hydration is complete.

After the other dry ingredients are combined with the re-hydrated potatoshreds, the ingredients and shreds are mixed continuously for about 3 toabout 5 minutes in a mixing vessel, such as a continuous mixer equippedwith a dough hook, available from Hobart Corporation. After mixing, thepotato shreds and other dry. ingredients are in the form of a doughhaving a moisture content of between about 55% and about 75%, preferablyabout 60% to about 72%, which can then be processed by extrusion toobtain the casing material. Prior to extrusion, the dough can sit atambient temperature for an indefinite amount of time, however a periodof up to about 1 hour is preferred for making an acceptable potato shredcasing.

The potato shred dough is then extruded through the multiple extrusionnozzle or a series of such multiple extrusion nozzles, each of whichalso has means for placing the filling within the axial cavity of thecasing material to form one, or two or more continuous ropes, eachhaving two or more axial cavities. The nozzle can be used with acommercial co-extruder, such as Model Nos. KN300, KN400, CN100 and 207from Rheon USA. The nozzle can also be used with non-traditionalextrusion equipment such as continuous vacuum stuffers, pumper-stufferequipment and other modified co-extrusion equipment. The filling iseither stuffed or injected into the casing or co-extruded with thecasing material through an inner extrusion segment.

The casing, or casing/filling as the case may be, is extruded incontinuous ropes comprising two or more axial cavities onto a conveyingsystem, such as a conveyor belt. In aspects of the invention where thesnack food product comprises two or more continuous ropes, a pluralityof continuous ropes are extruded onto the same conveying system. Theplurality of continuous ropes are then attached on the conveying systemby the orientation of the continuous ropes and forward movement of theconveyor and/or by physical means, such as the application of force bywedges and/or guides. The attached continuous ropes comprise axialindented ridge type connectors having a radial width of about 2 to about12 millimeters between attached adjacent multiple continuous ropes,formed by the orientation of the ropes, in addition to the axialindented ridge type connectors formed during extrusion.

If the ropes are not of a desired size or shape after extrusion, theprocess can further comprise the step of adjusting the size or shape bya roll over operation. While on the conveyor, the continuous ropes orattached continuous ropes move beneath one or two or more stationaryrollers which can be adjusted to obtain a desired thickness and shape ofthe casings. As the casings move on the conveyor under the roller orrollers, the casings are compressed.

The continuous ropes are cut to desired size and crimped on each end toseal each end with casing material thereby generally enclosing thefilling material within the axial cavities and the ends to obtainuncooked cut casings. The cutting and crimping operation generallyoccurs after the roll over operation if this step is employed. Thecutting and crimping of the product can occur simultaneously by cuttingwith a blade while the continuous ropes are moving along the conveyingsystem. The actual dimensions of uncooked cut casings can be varied toaccommodate a variety of means for reconstituting and heating theproduct, such as a conventional residential toaster or toaster oven.After the continuous ropes are cut and crimped, the uncooked casings arethen cooked by being fried, baked, par-fried or par-baked to prepare thecooked product for freezing. The product can be fried, par-fried, bakedor par-baked, in any frying or baking apparatus, non-limiting examplesof which are a Pitco Frialator Model E14 from Pitco Frialator, Concord,N.H., USA for frying or par-frying or a Model UB-3T baking oven fromNU-VU, Menominee, Mich., USA for baking or par-baking. Freezing may bedone in any commercial type freezer, preferably in a blast type freezer,such as a Rinox Blast Chiller and Freezer available from ServoliftEastern Co., Boston, Mass., U.S.A.

During the cooking process, particularly when the uncooked cut casingsare fried or par-fried, a certain amount of moisture from the casingmaterial will be replaced with fat or oil, despite the gum/starch filmthat retards moisture loss. Generally, the casing material willexperience a moisture loss during cooking of about 8% to about 15% andwill experience about 6% to about 10% fat or oil uptake during cooking.The moisture content of the casing of the cooked product is about 45% toabout 60%. Because moisture in the casing is replaced by oil, themoisture content of the casing regulates oil uptake as higher moisturecontent in the casing (e.g. more than about 75%) would result in greateramounts of moisture loss and oil uptake during cooking.

The axial indented ridge type connectors serve to provide the productwith break apart functionality. The axial indented ridge type connectorsalso provide structural rigidity to the product.

The cellulose gum and starch, preferably modified starch, form a filmaround the casing and seals the potato shred matrix by filling the voidspaces of the exposed surfaces of the casing which provides the casingwith structural integrity. The gum also regulates fat uptake duringfrying, or cooking and inhibits fat from leaching during reconstitution.As set forth in Table I, inclusion of cellulose gum in amounts from 0.5%to 2.0% reduces fat uptake from between 16.5% and 27.0%, and the casingformula should include at least about 0.5% cellulose gum. The filling ofthe void spaces and film also retards oil from leaching from the productduring reconstitution and provides for a crispier texture when theproduct is reconstituted, particularly by re-heating in a toaster ortoaster oven. Preferred cellulose gums are microcrystalline cellulose,methylcellulose, carboxymethylcellulose, hydroxyethylcellulose,hydroxypropylcellulose, hydroxypropylmethylcellulose and combinationsthereof. AVICEL® Type C-611F cellulose gel available from FMCCorporation, Philadelphia, Pa., USA can be used in the casing formula.The gum may be added in powder form with the other dry ingredients ordispersed in the water used to re-hydrate the dehydrated potato shreds.Physically or chemically modified starches are preferred because thesetypes of starches impart better freeze thaw stability than nativestarches.

TABLE I Fat uptake (%, casing) Cellulose Gum (fried at 375° F., 90 (%,w/w in casing) seconds) % fat uptake reduction 0 11.5 reference 0.5 9.616.5 1.0 8.8 23.5 2.0 8.4 27.0 Note: the fat content of casing beforefry is 0.1 to 0.15%

The tube shaped snack food product has an exterior surface texturereminiscent of processed hash brown potato patties. The potato shredmatrix creates an irregular surface with shreds slightly protruding fromthe surface and the cellulose gum and starch seal the surface. Thissurface texture results in a hand held convenience snack food typeproduct with visual appeal and organoleptically enhanced propertiesbecause of the textured surface.

The potato shreds having irregular and random sizes results in a crosslinked potato shred matrix throughout the casing material. This crosslinking enhances the structural integrity of the casing. The gum andstarch seal the exposed surfaces of the casing material and fills thevoid space in the matrix at the exposed surfaces of the casing thusfixing the cross-linked shreds in the form of a matrix providing furtherproduct stability and sets the textured surface of the product. Thematrix also provides a casing material with greater homogeneity-suchthat extrusion is facilitated and the casing material is devoid ofundesirable gaps which affect product appearance and the potential forfilling material to escape from the casing during extrusion andprocessing or when the finished product is reconstituted.

EXAMPLES Example I

Dehydrated potato shreds having an average cross section of about 2.5millimeters by about 4.8 millimeters, with random length, werere-hydrated with water at 75° C. in a Hobart 80 quart mixer for a totaltime of 35 minutes with interval mixing of 1.5 minutes at speed 1 every5 minutes. After re-hydration, the other dry ingredients were combinedwith the potato shreds in the Hobart mixer and then mixed on acontinuous basis at speed 2 for 5 minutes to form the casing material.The composition of the casing material and ingredients is set forth inTable II. The casing material comprised AVICEL Type CL-611F cellulosegel available from FMC Corporation and Crisp Film Starch available fromNational Starch, Bridgewater, N.J., USA.

TABLE II Dehydrated Potato Shreds 22.5% Dried Potato Flake 5.0% Starch(Modified) 2.0% Sugar 0.5% Salt 1.0% Water 67.0% Flavorings 1.0%Cellulose Gum 1.0%

Casings (e.g continuous ropes) having two axial cavities were extrudedusing a Rheon 207 co-extruder, equipped with the multiple extrusionnozzle, with a casing setting at 3 and filling setting at low. The axialcavities of the potato shred casing were filled with restricted meltcheese sauce available from Kraft Foods Ingredients, Memphis, Tenn.,U.S.A. The extruded continuous ropes were conveyed on a conveyor and cutby hand to length of approximately 85 to 110 millimeters to obtainuncooked cut casings. The uncooked cut casings were then cooked byimmersion in partially hydrogenated oil at a temperature of 375° F. fora period of 90 seconds using a Pitco Frialator Model E14 electric fryer.The cooked product was then cooled, frozen in a Rinox Blast Chiller andFreezer available from Servolift Eastern Company and reconstituted in aconventional toaster.

The snack food performed adequately during extrusion, frying andreconstitution. Reconstituted product was observed as having acceptableproduct attributes and organoleptic characteristics.

Example II

Dehydrated potato shreds having an average cross section of about 2.5millimeters by about 4.8 millimeters, with random length, werere-hydrated with water at 75° C. in a Hobart 80 quart mixer for a totaltime of 35 minutes with interval mixing of 1.5 minutes at speed 1 every5 minutes. After re-hydration, the other dry ingredients were combinedwith the potato shreds in the Hobart mixer and then mixed on acontinuous basis at speed 2 for 5 minutes to form the casing material.The composition of the casing material and ingredients is set forth inTable III. The casing material comprised AVICEL Type CL-611F cellulosegel available from FMC Corporation and Crisp Film Starch available fromNational Starch, Bridgewater, N.J., USA.

TABLE III Dehydrated Potato Shreds 22.5% Dried Potato Flake 5.0% Starch(Modified) 2.0% Sugar 0.5% Salt 1.0% Water 67.0% Flavorings 1.0%Cellulose Gum 1.0%

Two casings were extruded using two Rheon 207 extruders, with dualnozzles having a ratio of 22/18 millimeters (outer diameter/innerdiameter) with a casing setting at 3 and filling setting at low. Thepotato shred casing was filled with restricted melt cheese sauceavailable from Kraft Foods Ingredients. The extruded multiple ropecasings were conveyed on a conveyor and the 2 ropes were physicallyattached and then compressed. The attached ropes were cut by hand tolength of approximately 85 to 110 millimeters to obtain uncooked cutcasings. The uncooked cut casings were then cooked by immersion inpartially hydrogenated oil at a temperature of 375° F. for a period of90 seconds using a Pitco Frialator Model E14 electric fryer. The cookedproduct was then cooled, frozen in a Rinox Blast Chiller and Freezeravailable from Servolift Eastern Company and reconstituted in aconventional toaster. The snack food performed adequately duringextrusion, frying and reconstitution.

Frozen product of Example II was subjected to scanning electronmicroscopy (SEM) to observe the outer surface of the product. Thetextured surface of the casing and a continuous potato shred matrix wereobserved. The casing had little, if any, discontinuities and cellulosegum was observed to be filling void spaces in the potato shred matrix onthe outer surface of the casing.

Example III

Casing formulas were prepared to evaluate the replacement of potatoshreds with dried potato flakes in the formula. The test casing formula,comprising a higher amount of dried potato flakes, is set forth in TableIV and a control formula is set forth in Table V. Twenty five percent ofthe dehydrated potato shreds in the control formula (Table V) arereplaced with dried potato flakes in the test formula (Table IV).

TABLE IV (TEST) Dehydrated Potato Shreds 16.99% Dried Potato Flake 9.66%Water 68.0% Flavorings (Onion Powder) 1.0% Dry Mix 4.35%

TABLE V (CONTROL) Dehydrated Potato Shreds 22.65% Dried Potato Flake4.00% Water 68.0% Flavorings (Onion Powder) 1.0% Dry Mix 4.35%

The dry mix comprises modified starch, sugar, salt and AVICEL TypeCL-611F cellulose gum from FMC Corporation. The casing was formulatedand extruded in accordance with the process and extrusion methods, andequipment described in Example II. Restricted melt cheese sauce fromKraft Foods was used for the filling material. The filled product had aratio of 75 parts casing to 25 parts filling.

The casings were hand cut into pieces and fried in a Model E14 electricfryer from Pitco Frialator in partially hydrogenated frying oil at atemperature of 375° F. Samples of the control and test runs were friedfor periods of 90, 120 and 150 seconds. The test samples comprising agreater amount of dried potato flake performed adequately. The driedpotato flake has significantly less cost than potato shreds, and potatoshred processing time, e.g. re-hydration, can be decreased with use ofmore dried potato flakes. Thus, the ability to use larger quantities ofdried potato flakes in lieu of potato shreds in the casing represents asubstantial cost savings.

We claim:
 1. A process for making a hand held convenience snack foodproduct comprising: a) re-hydrating dehydrated potato shreds with water,b) combining said potato shreds with dry ingredients and mixingcontinuously to form a dough having a moisture content of about 55% toabout 75% and, optionally, allowing the dough to sit at ambienttemperature prior to further processing, c) extruding the dough in atleast one extruder equipped with a multiple extrusion nozzle comprisingi) an outer extrusion segment, said outer extrusion segment comprisingan outer surface, an opening, an inner surface, a hollow section definedby said inner surface and an outer extrusion port comprising an innerwall, said hollow section terminating at one end at said opening and atthe opposite end at said outer extrusion port and ii) an inner extrusionsegment comprising a threaded section, a shaped body, two or morechannels and at least one inner extrusion port comprising two or moreaxially adjacent inner port openings and an outer wall, said shaped bodyterminating at one end at said threaded section and at the other end atsaid at least one inner extrusion port and said channels beinginterspaced within said body and having diverging axes which originateat a point between said threaded section and said at least one innerextrusion port and terminating at said two or more inner port openings,said channels being aligned with said two or more inner port openings,wherein said inner extrusion segment is inserted into said hollowsection of said outer extrusion segment such that said inner extrusionsegment and said outer extrusion segment are aligned radially forming anannular space defined by said inner wall of said outer extrusion portand said outer wall of said inner extrusion port, to form at least onecontinuous rope having at least one inner wall, an outer wall and two ormore axial cavities defined by said inner wall by movement of said doughthrough said annular space, d) filling said two or more axial cavitieswith filling material, e) cutting and crimping said continuous rope toform at least one uncooked cut casing, f) cooking said at least oneuncooked cut casing to obtain a product, and g) freezing said product.2. The process of claim 1 comprising the additional step of compressingsaid continuous rope.
 3. The process of claim 1 wherein said dough has amoisture content of about 60% to about 72%.
 4. The process of claim 1wherein said potato shreds are re-hydrated by mixing said potato shredsin water at a temperature of about 45° C. to about 95° C. for about 18to 60 minutes.
 5. The process of claim 1 wherein said potato shreds andsaid dry ingredients are mixed for about 3 to about 5 minutes.
 6. Theprocess of claim 1 wherein said inner extrusion segment has two channelsand two inner port openings.
 7. The process of claim 1 wherein saidinner extrusion segment has three channels and three inner portopenings.
 8. The process of claim 1 wherein said multiple extrusionnozzle further comprises at least one set of indentations at opposingpositions on said inner surface of said outer extrusion segment whereinsaid set of indentations is aligned adjacent to corresponding inner portopenings.
 9. The process of claim 1 wherein cellulose gum is dispersedin said water prior to the re-hydration step.
 10. The process of claim 1wherein said filling material is selected from the group consistingessentially of meat, cheese, processed diary products, flavorings,sauces, spices and combinations thereof.
 11. The process of claim 1wherein said dry ingredients comprise dried potato flakes, starch,sweetener, cellulose gum and flavorings.
 12. The process of claim 11wherein said cellulose gum is selected from the group consistingessentially of microcrystalline cellulose, methylcellulose,carboxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose,hydroxypropylmethylcellulose and combinations thereof.
 13. The processof claim 11 wherein said starch is a modified starch.
 14. The process ofclaim 11 having from about 3% to about 10% dried potato flakes on a wetbasis.
 15. A process for making a hand held convenience snack foodproduct comprising: a) providing fresh cut potato shreds, b) combiningsaid potato shreds with dried potato flakes, starch, sweetener,cellulose gum, flavorings and other ingredients and mixing continuouslyfor about 3 to about 5 minutes to form a dough having a moisture contentof about 55% to about 75% and, optionally, allowing the dough to sit atambient temperature prior to further processing, c) extruding the doughin at least one extruder equipped with a multiple extrusion nozzlecomprising i) an outer extrusion segment, said outer extrusion segmentcomprising an outer surface, an opening, an inner surface, a hollowsection defined by said inner surface and an outer extrusion portcomprising an inner wall, said hollow section terminating at one end atsaid opening and at the opposite end at said outer extrusion port andii) an inner extrusion segment comprising a threaded section, a shapedbody, two or more channels and at least one inner extrusion portcomprising two or more axially adjacent inner port openings and an outerwall, said shaped body terminating at one end at said threaded sectionand at the other end at said at least one inner extrusion port and saidchannels being interspaced within said shaped body and having divergingaxes which originate at a point between said threaded section and saidat least one inner extrusion port and terminating at said two or moreinner port openings, said channels being aligned with said two or moreinner port openings, wherein said inner extrusion segment is insertedinto said hollow section of said outer extrusion segment such that saidinner extrusion segment and said outer extrusion segment are alignedradially forming an annular space defined by said inner wall of saidouter extrusion port and said outer wall of said inner extrusion port,to form at least one continuous rope having at least one inner wall, anouter wall and two or more axial cavities defined by said inner wall bymovement of said dough through said annular space, d) filling said twoor more axial cavities with filling material, e) cutting and crimpingsaid continuous rope to form at least one uncooked cut casing, f)cooking said at least one uncooked cut casing to obtain a product, andg) freezing said product.
 16. The process of claim 15 comprising theadditional step of compressing said continuous rope.
 17. The process ofclaim 15 wherein said inner extrusion segment has two channels and twoinner port openings.
 18. The process of claim 15 wherein said innerextrusion segment has three channels and three inner port openings. 19.The process of claim 15 wherein said multiple extrusion nozzle furthercomprises at least one set of indentations at opposing positions on saidinner surface of said outer extrusion segment wherein said set ofindentations is aligned adjacent to corresponding inner port openings.20. The process of claim 15 wherein said dough has a moisture content ofabout 60% to about 72%.
 21. The process of claim 15 wherein saidcellulose gum is selected from the group consisting essentially ofmicrocrystalline cellulose, methylcellulose, carboxymethylcellulose,hydroxyethylcellulose, hydroxypropylcellulose,hydroxypropylmethylcellulose and combinations thereof.
 22. The processof claim 15 wherein said starch is modified starch.
 23. The process ofclaim 15 having from about 3% to about 10% dried potato flakes on a wetbasis.